Wallboard Tape And Method Of Using Same

ABSTRACT

The present invention is a wallboard tape that simplifies the covering of elongated wallboard joints formed by the abutting of adjacent wallboards. The wallboard tape includes a fibrous paper tape having a resin-impregnated body and a water-soluble, water-activated adhesive layer applied to a surface of the body. The resin impregnated body remains relatively non-moisture absorbent during wetting of the adhesive layer thereby allowing the adhesive layer to dry several minutes after installation of the tape over a wall joint.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No. 11/129,642 filed May 16, 2005, hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates generally to the construction and building trade, and more particularly to an improved unique version of paper-fiber wallboard tape. The wallboard tape of the present invention is used to join gypsum drywall segments and to conceal the fusion of the segments in a smooth seamless transition from section to section.

BACKGROUND OF THE INVENTION

The standard established procedure for joining wallboards is set in motion after securing wallboards to the building frame. Once secured, a layer of joint compound is applied (mud or plaster) to cover the space between drywall sections. Joint tape is then embedded within the compound running the length of the wallboard joint.

The generally accepted conventional tape calls for 80-100 pound kraft paper with 0-2% wet strength properties. These conventional drywall tapes are usually formulated from pulp becoming kraft paper as the finished product. Specifications of paper used require set standards of high tensile fiber composition with wet, dry and cross tear strengths as the standard determined properties (ASTM-475). It is important to note that the above kraft paper allows the penetration of the moist compound into the paper itself.

These paper tapes are produced with either a spark-perforated surface or a plain surface gypsum ribbon. Both paper types are typically slightly sanded creating a fine nap for greater adhesion qualities. These tapes include a defined center margin for an accurate taping guide, particularly for corners. The benefits of spark-perforation are a faster and even drying outcome.

After this tape application is completed, an important drying period is required. Depending upon the ambient atmosphere, the aeration time is approximately 8 to 12 hours. The drying is a critical factor so that the joint environment is free of moisture. Moisture breeds mold and mildew that can spread throughout the wallboard perpetuating building decay and promoting a health hazard. This is equally true where the wallboard is of other than gypsum construction.

After the above step is completed, a second coat of compound covers the tape, again needing to dry fully. Smooth sanding completes preparation for the final finishing, painting, etc.

This procedure, very well established, is easily executed and requires two time-consuming drying periods, regardless of the basic components (animal, starch, or polyvinyl acetate) found in the majority of compounds used.

In addition to the paper fiber tape, the art also employs fiberglass mesh tape as a joint seam. It is available in either a self-adhesive roll (one side adhesively coated) or a plain, non-adhesive staple roll, depending upon the user's preference. The benefit of this tape is a grid fabrication that interlocks with the initial layer of compound. The general practice allows for the mesh as a first stage of application, and then follows the same procedures including the two coats of compound that require extensive drying time as described above. The drywall mesh tape is more expensive than conventional paper tape, thus being used more often for repairs than for wallboard joint connection.

SUMMARY OF THE INVENTION

In brief, the present invention contemplates the provision of a fibrous or paper wallboard tape, which may be employed without the necessity of first applying an initial coat of compound or plaster. The merits of this are both economical and practical from the vantage point of the end user.

To this end, the inner surface of the tape with the general basic conventional product qualities is coated with a formulated water soluble, water-activated adhesive that may contain mold and mildew inhibitors. The tape is inert until wetted. Once activated by water, the tape adhesion to the adjacent joint follows. The adhesive begins to bond as it aerates.

Drying is quick as the tape ventilation properties allow moisture to evaporate rapidly via the perforations. Substantial wetting of the paper tape is of little consequence to the bonding properties. The absence of the bedding coat allows moisture to evaporate quickly from the underlying joint. In less than one hour after beginning the process, the final coat of either plaster or compound may be applied.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the wallboard tape according to a first embodiment of the present invention;

FIG. 2 is a bottom view of the wallboard tape according to a second embodiment of the present invention; and

FIG. 3 is a bottom view of the wallboard tape according to a third embodiment of the present invention.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENT

In accordance with the invention, the disclosed embodiment may include many forms, although the majority of use is in the form of an elongated resin impregnated tape. Other such forms may be rectangles, squares, circles, and frames of those shapes, as well as appliques combined with other materials for use as adjuncts or as accessories in activities associated with the construction industry and general crafts where applicable.

As shown in FIG. 1, the first embodiment 10 of the present invention comprises of a first layer of fibrous material 11 and a water-soluble, water-activated adhesive layer 12 applied to one surface thereof. The tape 10 may be conveniently packaged in roll form as known in the art. The tape 10 may be in a variety of widths, mostly ranging between one-eighth inch and six inches, and lengths from 20 feet to 600 feet, most commonly approximately 2 inches by 300 feet, which will be normally adequate to cover the gaps formed by abutting wallboards, and more specifically, about 2 1/16 inches by 250 feet.

As shown in FIG. 2, extending between the outer surface and the inner surface of the fibrous layer 21 may be air-conducting perforations 22 covering substantially the entire area of the tape 20 at intervals of one-eighth inch, which may be either punched or spark-perforated.

As is known in the art and shown in FIG. 3, a preferred centerfold 33 may be employed to enable the tape 30 to be used with angle joints, as well as joints formed by inside corners of a wall. This centerfold 33, known in the art as a center margin, serves as a rule guide for the user.

The adhesive layer 12 is preferably roll-coated using known techniques to conventional thickness. Since resin impregnated paper is mechanically stronger than kraft paper, the fibrous material 11 may be of a lesser thickness than the conventional product. The adhesive 12 may contain mold and mildew inhibitors as described in more detail below.

The tape 10 may be employed either by moistening the adhesive layer 12 using a wetted sponge (not shown), immersing the tape roll in a vessel of water, or a dispensing device that may or may not incorporate a wetted sponge. It is possible to wet the exposed surface of the wallboard adjacent to the joint so that moisture transfer from the wallboard wets the adhesive surface 12 of the tape 10 when applied. Preferably, a sponge brushing of the applied tape length across the joint takes place after application to ensure proper bonding wetness and a smooth drying result. During this period, the tape 10 may be accurately positioned if not originally properly aligned without difficulty. The wetting is facilitated by the fact that the paper layer 11 which is resin impregnated does not absorb and retain substantial amounts of moisture, which also facilitates subsequent drying of the adhesive. As a result, the tape 10 is sufficiently dried and ready for the application of a finish coat of plaster compound after several minutes, specifically, after 30 minutes to an hour or in less than one hour.

An important feature to be noted is that within the adhesive formula there may be provided mold and mildew inhibitors for preventing bacterial growth. While a variety of such agents are commercially available, a preferred composition is sold under the trademark “Sil-75”, a liquid polysiloxane available from the Dow Chemical Corporation of Midland, Mich. This composition is preferably incorporated into the adhesive by mixing in a proportion of less than five percent by volume. The preferred and most effective embodiment, however, is in a range of one to two percent by volume.

It will be observed that since the adhesive layer is not activated prior to actual application to the joint, should any longitudinal twisting occur as the strip is handled, it can be readily straightened as the strip is applied without danger of the adhering layer adhering to itself, as is the case where pressure sensitive adhesives are employed. Of equal importance is the fact that the cost of manufacture of the disclosed tape is only marginally greater than that of conventional paper tape, and well within the price range of the highest quality fiberglass tape.

With the elimination of the initial layer of compound, fewer person-hours are necessary to accomplish the drywall joint task and a great savings emerges. The improved tape may be used in connection with wallboards of other than gypsum type with equal facilities.

The present invention is not limited to the precise details of structure described in the specification, for obvious modifications will occur to those skilled in the art to which the invention pertains. And although the present invention has been described in detail and with particularity, it will be appreciated by those skilled in this art that changes and modifications can be made therein without departing from the scope and spirit of the invention. 

1-6. (canceled)
 7. A wallboard tape for covering elongated joints in gypsum and other type wallboards comprising: a fibrous paper tape having a resin-impregnated body defining first and second planar surfaces; and a water-soluble, water-activated adhesive layer applied to one of said first and second surfaces, whereby the resin impregnated body remains relatively non-moisture absorbent during wetting of the adhesive layer thereby allowing the adhesive layer to dry several minutes after installation of the tape over a wall joint.
 8. The wallboard tape of claim 7 wherein the wallboard tape is elongated.
 9. The wallboard tape of claim 8 wherein the elongated wallboard tape is packaged in roll form.
 10. The wallboard tape of claim 9 wherein the elongated wallboard tape has a width of approximately ⅛-6 inches and a length of approximately 20-600 feet.
 11. The wallboard tape of claim 7 wherein the tape is in the form of rectangles, squares, circles, and/or frames of rectangles, squares or circles.
 12. The wallboard tape of claim 7 wherein the wallboard tape is used in conjunction with a wetted sponge.
 13. The wallboard tape of claim 7 wherein the wallboard tape is used in conjunction with a vessel of water.
 14. The wallboard tape of claim 7 wherein the wallboard tape is used in conjunction with a dispensing device.
 15. The wallboard tape of claim 7 further comprising: a mold and mildew inhibitor.
 16. The wallboard tape of claim 15 wherein the mold and mildew inhibitor is a liquid polysiloxane.
 17. The wallboard tape of claim 16 wherein the mold and mildew inhibitor is incorporated into the water-soluble, water-activated adhesive layer by mixing in a proportion of less than five percent by volume. 